Car top carrier

ABSTRACT

The invention provides improvements for an enclosed carrier configured for mounting on top of a car.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.11/219,578 filed Sep. 2, 2005 which is a divisional application of U.S.patent application Ser. No. 10/767,398 filed Jan. 28, 2004 which isbased upon and claims priority under 35 U.S.C. §119 from U.S.Provisional Patent Application Ser. No. 60/443,487 filed Jan. 28, 2003and from U.S. patent application Ser. No. 10/662,123 filed Sep. 11,2003, all of which is incorporated herein by reference in its entiretyfor all purposes.

FIELD OF THE INVENTION

The invention relates to assemblies for carrying cargo on a vehicle. Inparticular, the invention provides improvements for a box or trunkdesigned for mounting on top of a car.

BACKGROUND OF THE INVENTION

In recent years car top carriers in the form of boxes or trunks havebecome quite popular. Enclosed carriers are preferable over conventionalopen racks for a variety of reasons. Enclosed carriers protect cargofrom the elements such as wind, rain, and snow. Enclosed carriers arealso more secure from theft or vandalism.

However, some car top boxes have problems which make them difficult orcumbersome to use. For example, some boxes use a labor intensive bracketsystem to secure the box on to the crossbars of a vehicle roof rack.Bracket systems typically require the installer to reach extensivelyover the top of the car. Such bracket systems are impractical,particularly for a short person. The installer may have to practicallyclimb into the open box to secure the brackets. This is especially aproblem for a user who frequently wants to install or remove the carrierfrom the car.

Another problem with some enclosed car top carriers is that they canonly be accessed from one side. Depending on where or how the vehicle isparked, or who is trying to access the carrier, it may be inconvenientor awkward to always access the box from the same side.

Another problem with car top trunks or boxes is that they are sometimesdifficult to open. Typically, there are several latches on the side ofthe box that opens. The user may have to operate multiple latchessimultaneously where the latches are separated by a long distance. Thismay require substantial strength, dexterity, and reach. Some boxes havean actuator that coordinates simultaneous release of multiple latchesbut still may require special handling such as lifting of the coverwhile manipulating the actuator or handle. Accordingly, there is a needfor enclosed car top carriers that are easy to mount on a vehicle andeasy to use.

SUMMARY OF THE INVENTION

An example of the invention uses a mounting assembly that is quick andeasy to install on a car. A preferred design uses a cam-operatedclamping device to grip crossbars on a vehicle rack. Another example ofthe invention uses coordinated hinge/latch devices to permit easyopening of the carrier from either side of a vehicle. Other examples andaspects of the invention are described in detail below.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side view of a car top carrier mounted on a vehicle.

FIG. 2 is an exploded view of a car top carrier.

FIG. 3 is a partial cut-away view of clamp 34 c in FIG. 1 gripping acrossbar.

FIGS. 4 and 5 are partial cut-away side views of the clamp in FIG. 3 asthe cam lever moves toward the release position.

FIG. 6 is a top view of the clamp in FIG. 3.

FIG. 7 is an end-on view of the clamp in FIG. 3.

FIG. 8 is an inside view of a car top carrier with four clamps gangedtogether.

FIG. 9 is an inside view of a car top carrier with two clamps gangedtogether.

FIGS. 10 and 11 are end views of a car top carrier showing opening ofthe box from opposing sides.

FIGS. 12-14 are side views of a hinge/latch mechanism, for example, asshown in FIG. 2.

FIG. 15 is a partial cut way view of a hinge/latch mechanism, forexample, as shown in FIG. 2.

FIGS. 16-18 are partial cut away views of a hinge/latch mechanism inoperation.

FIG. 19 is an isolated side view of a lid support device, for example,as shown in FIG. 2.

DESCRIPTION OF THE INVENTION

FIG. 1 shows car top carrier 20 mounted on vehicle 22. Car top carrier20 includes top 24 and bottom 26 mounted on crossbars 28 on the top ofcar 22.

FIG. 2 shows an exploded view of car top carrier or box 20. Mountinghardware is provided for easily securing carrier 20 to the vehicle rack.For example, four mounting mechanisms 34 a-d may be provided for thispurpose. Each mounting mechanism includes a cam lever for operating ajaw mechanism to clamp around a crossbar, as explained in more detailbelow. The clamps may be provided completely preassembled with the box.The clamps never need to be disassembled as the carrier is put on andoff one or more cars through the life of the product. Each clamp may beadjustable to grip, with variable force, crossbars of differentdimensions. The clamps may also be adjustable to different locations onthe floor of the box, for example, along an axis parallel to thedirection of vehicle travel. The clamps are preferably configured sothat once the carrier clamps are adjusted for a particular vehicleconfiguration, the carrier can be easily installed or removed by simplymanipulating each cam lever with a single, one step, switch, toggle,rotation, stroke or other quick-action, for example, with an over-centerassist mechanism.

Sets of hinge/latch mechanisms may also be provided on each side ofcarrier 20 to allow opening of the carrier from opposite sides. In FIG.2, hinge/latch mechanisms 40 a-40 c are mounted on one side of carrier20 to connect top 24 to bottom 26. Similarly, on the other side ofcarrier 20, hinge/latch mechanisms 42 a-42 c connect top 24 to bottom26. Actuating bar 44 is mounted inside carrier 20 for operating andsynchronizing hinge/latch function of mechanisms 40 a-40 c. Actuatingbar 44 may be operated, i.e., moved forward and backward relative to thelong axis of carrier 20, by manipulating switch, handle, or key device46 from the exterior of carrier 20. A similar actuating bar (not shown)is used to operate hinge/latch mechanisms 42 a-c via switch, handle, orkey device 50.

Lid supports 54 a and 54 b are mounted at the front and back ends ofcarrier 20, connecting top 24 to bottom 26. Lid supports 54 a and 54 bstabilize top 24 when moving between open and closed positions. Lidsupports 54 a and 54 b may also limit the extent of potential opening ofcarrier 20. For example, lid supports 54 a, 54 b, may limit the extentof opening on either side of carrier 20 to approximately 16-inches.Longitudinal ribs or indentations 58 may be formed in carrier top 24 toprovide stiffening and increased strength for carrier 20, and may alsobe desirable aesthetically.

FIGS. 3-7 show details of one of the four mounting mechanisms, forexample, as shown in FIG. 2. FIG. 3 is a side view of one of clamps 34,with a portion of bottom 26 of carrier 20 cut-away. In closed position,cam lever 38 seats against floor 33 of bottom 26. Cam lever 38 actsthrough cam portion 41, shaft member 43, bolt 45, barrel nut 47, andaxle 49 to apply a force holding crossbar 28 tightly clamped betweenmovable jaw portion 51 and stationary jaw portion 53.

FIGS. 4 and 5 show details of clamp 34 moving to an unclamped position.Cam lever 38 pivots around shaft member 43. The shape of cam portion 41and the position of shaft member 43 causes opening and closing ofmovable jaw portion 51 relative to stationary jaw portion 53 when camlever 38 is rotated between different positions as shown in FIGS. 3 to5. The jaw portions may define openings of different shapes for variouspurposes. The jaw portions in FIGS. 3-5 define an elongate curvedopening, or oval shape to accommodate crossbars having differentcross-sectional shapes. Cam portion 41 is shaped so that as lever 38rotates around shaft member 43 the distance between shaft member 43 andfloor 33 is altered, thus causing corresponding pivotal movement of jawportion 51 toward or away from fixed stationary jaw potion 53 mounted onfloor 33. An over-center mechanism is used so that a maximum height ofshaft member 43 is reached at an intermediate point, for example,approximately at the location shown in FIG. 4. This way lever 38 tendsto stay locked in the closed position shown in FIG. 3, and tends tospring to the unlocked position when lever 38 is moved over-center inthe opposite direction, as shown in FIG. 5. Movable jaw portion 51pivots around axle structure 49. Movable jaw portion 51 is elongate,with an initial portion 55 angled so as to guide crossbar 28 intoposition between movable jaw portion 51 and stationary jaw portion 53.Movable jaw portion 51 has a concave inner surface 57 which contactscrossbar 28 when the jaw is closed, and which is configured forgripping. Concave inner surface 57 may have a cushion or pad 59 nearaxle 49. Stationary jaw portion 53 may have side tabs 61 to guidemovable jaw portion 51 when clamp 34 is moved to the closed position.

Clamp 34 is mounted on floor 33 of carrier bottom 26 by bolt 45, withbarrel nut 47 serving us an anchor pivot for bolt 45. In addition, afirst oversize knob 63 turns bolt 45 to move barrel nut 47 closer to orfarther away from shaft member 43, thereby providing a gross adjustmentmechanism for the tightness of the clamping action. Movable jaw portion51 clamps around crossbar 28. In FIGS. 3-5, arrow 64 indicates thedirection of forward travel of vehicle 26. Movable jaw portion 51preferably is oriented to open in the forward direction to make carrier20 less likely to be dislodged from vehicle 22 in a high-impact forwardcollision.

FIG. 6 shows a top view of clamp 34. Bolt 45 passes from the inside ofcar top carrier 20 to the outside through floor 33 of carrier bottom 26via slot 66 which is aligned with the long axis of car top carrier 20.Slot 66 allows adjustment of the location of clamp 34 along the longaxis of car top carrier 20. Finger tabs 68 facilitate prying or liftingof cam lever 38 away from floor 33 when opening clamp 34. Cam lever 38is shaped to provide clearance for first oversize knob 62 when cam lever38 is moved between open and closed positions. A second oversize knob 70provides for tightening or loosening of fastener 72 passing through slot66 to stationary jaw component 53 to prevent or allow motion of clamp 34in slot 66. Floor 33 of bottom 30 is shaped in the form of a ridge orrail 74 to complement the shape of clamp 34 and to aid in seating camlever 38 against floor 33 when clamp 34 is in the closed position,thereby providing repeatable and secure alignment.

FIG. 7 is an end-on view of clamp 34, as shown in FIG. 6. Shaft member43 may include curvature away from barrel nut 47 so as to provide springaction during operation of clamp 34.

FIG. 8 shows a top view of the interior of car top carrier 80 includingfour clamps 82 a-d. In this example, all four clamps 82 a-d are gangedby connectors 84 and 86. Ganging clamps allows multiple clamps to beoperated with a single movement, step, or manipulation. Ganged clampconfigurations may also make it easier to operate clamps locateddistally from the installer's vantage point.

FIG. 9 shows another example. A top view of car top carrier 90 has twoclamps 92 a and 92 b. In this example, two clamps 92 a and 92 b arelocated on front and rear crossbars, and are ganged by connector 94 sothat clamps 92 a and 92 b open and close together.

Any number of clamps may be used to fasten a container on a set ofcrossbars on top of a vehicle. For example, one, two or more clamps maybe used to secure a container on a front crossbar. Similarly, one, twoor more clamps may be used to secure a container to a rear crossbar. Forsome purposes a single clamp may be sufficient, for example, on thefront crossbar with the container merely resting on the back crossbar.In other instances, a single clamp may be used on each crossbar, ormultiple clamps may be used on one or both crossbars.

Any combination of clamps may be ganged. For example, it may beadvantageous to have a clamp which is closest to the hinge side of a box(distal clamp) ganged to a clamp on the opening side of the box(proximal clamp) so that operation of the proximal clamp automaticallyoperates a corresponding distal clamp.

It may also be advantageous to have an extended handle or actuatorconnected to the distal clamp so that the distal clamp can be operatedwith minimal reaching from the open side of the container.

A clamp, as described above, may also be modified to provide automaticclamping. For example, the movable jaw portion may be spring biasedtoward the closed position. The lip of the jaw may be configured tocause opening of the jaw as the box slides forward across the top of thecrossbars. Once the jaw encompasses the crossbar, it springs back to asecure closed position. The jaw is further configured so that it cannotbe opened without a manipulation, for example, switch or lever-operated,action inside the box. This type of fastener may be referred to as “seatbelt type engagement.”

A jaw member as described above, may have different shapes. For example,the jaw member may be generically shaped to fit around differentlyshaped or dimensioned crossbars. Alternatively, the jaw member may becustom-shaped to fit around a specific crossbar configuration. Forexample, the jaw member may have a partially rectangular inner surfacefor fitting around a rectangular or square cross bar.

Clamping devices should be designed to minimize manufacturing costs andcomplexity. For example, a rail with a slot, as described above, may bemolded into the floor of a box. A stationary jaw portion, movable jawportion, and cam lever may be separately molded pieces.

Different kinds of actuators may be used to operate the jaw assembly.For example, an actuator may be a differently-shaped cam, or may be ascrew mechanism using a threaded member. A cam lever may operate indifferent directions other than parallel to the long axis of a containeras described above. Clamp mechanisms, as described above, may also beimplemented to connect other types of apparatus to crossbars on top of avehicle.

The clamp mechanisms shown and described herein may be implemented onboxes with any type of hinge and/or latch mechanism. For example, theclamping devices may be used on a box with dual functioning hinges thatcan operate as a hinge or a latch, for example, as described in U.S.Pat. No. 5,823,411 and U.S. Provisional Patent Application No.60/443,437, each of which is hereby incorporated by reference in itsentirety.

FIGS. 10 and 11 show end views of car top carrier 20 opened alternatelyfrom opposite sides. This feature of carrier 20 is made possible bydual-functioning hinge/latch mechanisms such as the examples describedin detail below.

FIGS. 12 and 13 are side views of a hinge/latch mechanism, for example,like 40 a-c and 42 a-c in FIG. 2. Mounting base, platform, or portion110 may be securely fastened, for example, by screws to 24 of carrier20. Receiving portion 120 may be fastened securely to a correspondinglocation on bottom 26 of carrier 20. In FIG. 12 hinge/latch mechanism 40a is oriented in position for securing top 32 to bottom 34 when carrier20 is closed. FIG. 13 shows the orientation of hinge/latch mechanism 40when the hinge/latch mechanisms on the opposite side of the box arefunctioning as a latch. Flared portion 140 of receiving portion 120permits a selected degree of motion of arm portion 112 relative toreceiving portion 120. FIG. 14 shows hinge/latch mechanism 40 operatingas a latch after enlarged end portion 114 has been released fromreceiving portion 120.

FIG. 15 shows a cut-away view of hinge/latch mechanism 40 with actuatingbar 44 removed. Plunger 150 is spring-biased upward against enlarged endportion 114. The spring helps the lid to pop up initially when openingthe container. As shown, enlarged end portion 114 has a spherical shapewhich allows mounting platform 110 multiple, even infinite, degrees ofmovement relative to receiving portion 120. This feature allows thehinge/latch device, not only the flexibility of acting as a hinge or alatch, but also permits the same hinge/latch configuration to be used oncarriers of many different shapes and geometries. When pawl 122 isrotated in the direction of arrow 152 and is sufficiently out of the wayof enlarged end portion 114, plunger 150 urges enlarged end portion 114upward so that it disengages from receiving portion 120 even when pawl122 is permitted to rotate back to its original orientation. The springand plunger mechanism makes it easier to open the carrier because oncethe actuating bar has simultaneously pushed multiple pawl members out ofthe way in each of the coordinated hinge/latch mechanisms, the latchesare disengaged without further manual movement or handling relative tocarrier top 24. To re-engage hinge/latch mechanism 40 a, enlarged endportion 114 is forced into receiving portion 120 until pawl 122 ispushed aside allowing enlarged end portion 114 to “snap” into place, asshown in FIG. 15. The springs may be selected such that very little, ifany, manual force is required, in addition to gravity, to latch the topclosed, somewhat analogous to the closing of a trunk on a car.

FIGS. 16-18 show movement of actuating bar 44 to disengage enlarged endportion 114 from receiving portion 120. As shown in FIG. 16, actuatingbar 44 has a projection 160 that is normally spaced away from endportion 162 of pawl member 122 when hinge/latch mechanism 40 a isfunctioning as a hinge. When actuating bar 144 is moved in the directionof arrow 164 in FIG. 17, projection 160 of actuating bar 144 contactsand pushes end portion 162 of pawl member 122. This eventually causesrotation of pawl member 122 out of the way of the main receiving channelin receiving portion 120, thus allowing enlarged end portion 114 todisengage receiving portion 120, enabling hinge/latch mechanism 40 a tofunction as a latch.

FIG. 19 shows a lid support, for example, such as 54 b in FIG. 2. Firstarm 202 may be connected to bottom 26 of carrier 20. Second arm 204 maybe connected to top 24 of carrier 20. First arm 202 is pivotallyconnected second arm 204. Spring 206 is contained in a pocket in firstarm 202. Spring 206 acts on slide or cam follower 208 which moves up anddown as second arm 204 is moved between open and closed positions.Second arm 204 has a cam portion 210 than contacts slide 208. The shapeof cam portion 206 determines the magnitude and direction of torqueexerted on second arm 204 about pivot point 212.

While the present invention has been particularly shown and describedwith reference to the foregoing preferred embodiments, those skilled inthe art will understand that many variations may be made therein withoutdeparting from the spirit and scope of the invention as variouslydescribed and defined above. The description of the invention should beunderstood to include all novel and non-obvious combinations of elementsdescribed herein.

1. A car top carrier comprising a box having opposing lateral sides, atop, a bottom, a front end, and a rear end, the bottom having a floor,the floor having an inner surface and an outer surface, the top and thebottom being connected via hinge mechanisms along the opposing lateralsides of the box, the hinge mechanisms being capable of unlatchingallowing the box to be alternately opened on opposing lateral sides ofthe box, strut members connecting the top to the bottom on the front andrear ends of the box to assist in holding the box open, a plurality ofpreassembled clamp devices mounted to the floor configured to secure thebox to a pair of crossbars on top of a vehicle, each clamp deviceincluding a jaw assembly extending from the outer surface of the floorand a corresponding tightening mechanism inside the box, the tighteningmechanism being operable to move the jaw assembly between open andclosed positions so that a clamp device may be secured to a crossbarwithout any manipulation of the clamp device outside of the box.
 2. Thecarrier of claim 1, wherein the tightening mechanism includes a screwdevice.
 3. The carrier of claim 2, wherein the screw device includes athreaded shaft connected to a handle, rotation of the handle causingmovement of the jaw assembly between open and closed positions.
 4. Thecarrier of claim 1, wherein the tightening mechanism includes a camlever, pivotal movement of the cam lever causing movement of the jawassembly between open and closed positions.
 5. The carrier of claim 1,wherein the jaw assembly includes first and second jaw portions.
 6. Thecarrier of claim 5, wherein the first jaw portion is moveable relativeto the floor.
 7. The carrier of claim 6, wherein the second jaw portionis fixed relative to the floor.
 8. The carrier of claim 5, wherein thefirst and second jaw extend from the outer surface of the floor defininga curved opening for receiving a crossbar.